Multi-panel sunroof system

ABSTRACT

A multi-panel sunroof employs at least three movable sunroof panels. In another aspect of the present invention, three sunroof panels are stacked upon each other in one or two different operating positions. A further aspect of the present invention provides for rearward opening movement of a front sunroof panel and forward opening movement of a rear sunroof panel.

CROSS-REFERENCE TO RELATED APPLICATION

This application is a divisional of U.S. patent application Ser. No. 11/316,382 filed on Dec. 22, 2005. The disclosure of the above application is incorporated herein by reference.

BACKGROUND OF THE INVENTION

The present invention relates generally to automotive vehicle sunroofs and more particularly to a multi-panel sunroof system.

It is common to employ single-panel sunroofs in automotive vehicles. More recently, various attempts have been made to increase the sunroof opening area in vehicles to maximize open roof area above all of the vehicle passengers especially as the front windshield header continues to move rearwardly for styling and aerodynamic reasons. For example, various multi-panel sunroofs have been considered to increase open roof area and are disclosed in the following U.S. Pat. Nos.: 5,746,475 entitled “Drive Mechanism for an Automotive Vehicle Sunroof Assembly” which issued to Caye et al. on May 5, 1998; 5,197,779 entitled “Power Sliding Sunroof” which issued to Mizuno et al. on Mar. 30, 1993; and 5,029,937 entitled “Roof System for Vehicle” which issued to Yamamoto on Jul. 9, 1991; all of which are incorporated by reference herein. While some of these patents offer significant improvements, the sunroof tracks take up considerable vertical space thereby encroaching on desired headroom of the vehicle occupants, and do not provide vertical access above the storage area of a sport utility vehicle or station wagon.

SUMMARY OF THE INVENTION

In accordance with the present invention, a multi-panel sunroof employs at least three movable sunroof panels. In another aspect of the present invention, three sunroof panels are stacked upon each other in one or two different operating positions. A further aspect of the present invention provides for rearward opening movement of a front sunroof panel and forward opening movement of a rear sunroof panel. Yet another aspect of the present invention provides for a unique locking member and hook structure of a sunroof movement mechanism. An additional aspect of the present invention sunroof system includes a sunroof slide block having a body, a diagonally extending camming surface, an opening therebetween, and a trailing ramp. A method of operating a sunroof system is also provided.

The multi-panel sunroof system of the present invention is advantageous over traditional constructions in that the present invention system employs a track having reduced vertical depth in order to maximize occupant head room within the vehicle. The present invention is further advantageous by maximizing opening area above the front and rear seat passengers while also allowing vertical opening access over the storage area of the vehicle, such that cargo can be stored therein and extend above the nominal roof plane. Furthermore, various embodiments of the present invention employ in-line, multi-panel tracks along each side rail of the vehicle which allows for the multiple sunroof panels to be substantially co-planar when closed (while being slightly curved to account for the normal vehicle styling curvature). The single common track on each vehicular side also reduces tooling and assembly costs, while reducing parts in an assembly plant. Additional advantages and features of the present invention will become apparent from the following description and appended claims, taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view, taken from a vehicular front left corner, showing the preferred embodiment of the present invention multi-panel sunroof system, with all of the sunroof panels closed;

FIG. 2 is a diagrammatic side view showing the sunroof system, with all of the panels closed;

FIG. 3 is a perspective view showing the sunroof system, with the front panel vented, and the central and rear panels closed;

FIG. 4 is a diagrammatic side view showing the sunroof system, with the front panel vented, and the central and rear panels closed;

FIG. 5 is a perspective view showing the sunroof system, with the front panel in an intermediate open position and the central and rear panels closed;

FIG. 6 is a diagrammatic side view showing the sunroof system, with the front panel in its intermediate open position and the central and rear panels closed;

FIG. 7A is a perspective view showing the sunroof system, with the front panel in its intermediate open position, the central panel in its closed position, and the rear panel in its open position;

FIG. 7B is a diagrammatic side view showing the sunroof system, with the front panel in its intermediate open position, the central panel in its closed position, and the rear panel in its open position;

FIG. 8 is a perspective view showing the sunroof system, with the front panel in its extended open position, the central panel in its open position, and the rear panel in its closed position;

FIG. 9 is a diagrammatic side view showing the sunroof system, with the front panel in its extended open position, the central panel in its open position, and the rear panel in its closed position;

FIG. 10 is a perspective view showing the sunroof system, with the front and central panels in their closed positions and the rear panel in its open position;

FIG. 11 is a diagrammatic side view showing the sunroof system, with the front and central panels in their closed positions and the rear panel in its open position;

FIG. 12 is a cross sectional view, taken along line 12-12 of FIG. 13, showing a track employed in the sunroof system;

FIG. 13 is a perspective view, taken from a vehicular front left corner, showing a portion of the sunroof system, with a left-hand front movement mechanism in a closed position;

FIG. 14 is a perspective view showing a portion of the sunroof system, with the front movement mechanism in a vented position;

FIG. 15 is a perspective view showing a portion of the sunroof system, with the front movement mechanism moved to a partly open position;

FIG. 16 is a perspective view, taken from a rear right vehicular corner, showing the front movement mechanism of the sunroof system;

FIG. 17 is a perspective view showing a portion of the sunroof system, with the front movement mechanism opened just before engagement to a central movement mechanism;

FIG. 18 is a perspective view showing a portion of the sunroof system, with the front movement mechanism opened just before engagement to the central movement mechanism;

FIG. 19 is a perspective view, taken from a front right vehicular corner, showing a portion of the sunroof system, with the front movement mechanism engaged with the central movement mechanism;

FIG. 20 is a perspective view showing the front movement mechanism of the sunroof system, disposed in its closed position;

FIG. 21A is a fragmentary perspective view showing the front movement mechanism of the sunroof system;

FIG. 21B is a cross sectional view, taken along line 21B-21B of FIG. 21A, showing the front movement mechanism of the sunroof system;

FIG. 21C is a cross sectional view, taken along line 21C-21C of FIG. 20, showing the front movement mechanism of the sunroof system;

FIG. 21D is a cross sectional view, taken along line 21D-21D of FIG. 20, showing the front movement mechanism of the sunroof system;

FIG. 22 is a perspective view, taken from a rear left vehicular corner, showing a left-hand rear movement mechanism of the sunroof system, in a collapsed and unlocked orientation;

FIG. 23 is a perspective view, like that of FIG. 22, showing the rear movement mechanism in a raised orientation;

FIG. 24A is a fragmentary perspective view showing a central movement mechanism of the sunroof system, disposed in a closed position;

FIG. 24B is a cross sectional view, taken along line 24B-24B of FIG. 24A, showing the central movement mechanism of the sunroof system;

FIG. 25 is a cross sectional view, taken along line 25-25 of FIG. 27, showing the rear movement mechanism of the sunroof assembly, disposed in a locked orientation;

FIG. 26 is a perspective view, taken from a front right vehicular corner, showing the central movement mechanism of the sunroof assembly, disposed in a closed position;

FIG. 27 is a perspective view, taken from a rear left vehicular corner, showing a left-hand rear movement mechanism of the sunroof system, disposed in its closed position;

FIG. 28A is a perspective view, taken from a front left vehicular corner, showing the rear movement mechanism of the sunroof system, disposed in its closed position;

FIG. 28B is a cross sectional view, taken along line 28B-28B of FIG. 28A, showing the rear movement mechanism of the sunroof system;

FIG. 29A is a perspective view, taken from a rear left vehicular corner, showing the rear movement mechanism of the sunroof system, disposed in a closed position;

FIG. 29B is cross sectional view, taken along line 29B-29B of FIG. 29A, showing the rear movement mechanism of the sunroof system;

FIGS. 30-40 are a series of side diagrammatic views showing movement orientations of the movement mechanisms of the sunroof system; and

FIG. 41 is a perspective view, taken from the rear left vehicular corner, showing track inserts associated with the front movement mechanism of the sunroof system.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

The preferred embodiment of a multi-panel sunroof system 61 of the present invention is employed in an automotive vehicle 62 as is shown in FIGS. 1 and 2. Multi-panel sunroof system 61 includes a front sunroof panel 63 coupled to a front movement mechanism 65, a central sunroof panel 67 coupled to a central movement mechanism 69, and a rear sunroof panel 71 coupled to a rear movement mechanism 73. The sunroof panels are each made from three dimensionally curved, generally transparent and rigid glass sheets. The sunroof panels have exterior surfaces 75 generally flush with each other and with the adjacent stationary roof panels 77 at a front header, rear header, and side rails or door uppers, along a somewhat horizontally curved plane. A contiguous roof opening 79 is defined by a sunroof periphery 81 in stationary roof panels 77, or a tub frame mounted thereto, as can be observed in FIGS. 7 and 8.

FIGS. 1 and 2 show all sunroof panels 63, 67 and 71 in their closed positions. FIGS. 3 and 4 show front sunroof panel 63 in its upwardly tilted venting position, to allow some air flow through an open space adjacent a rear edge thereof, while central and rear sunroof panels 67 and 71, respectively, are in their closed positions. Furthermore, FIGS. 5 and 6 illustrate front sunroof panel 63 rearwardly moved to an intermediate open position, in a spoiler-type orientation stacked above the closed central sunroof panel 67, while rear sunroof panel 71 is in its closed position. FIGS. 7 and 7A show front and central sunroof panels 63 and 67, respectively, in the positions discussed with regard to FIG. 6, but rear sunroof panel 71 is forwardly moved to its open position dropped below central sunroof panel 67 in a three panel stacked configuration. Moreover, FIGS. 8 and 9 illustrate the same three panel stacked configuration but with front sunroof panel 63 moved to its extended open position, central sunroof panel 67, rearwardly moved to its open position, and rear sunroof panel 71 in its closed position. Finally, FIGS. 10 and 11 represent front and central sunroof panels 63 and 67, respectively, disposed in their closed positions with rear sunroof panel 71 moved to its open position to allow vertical cargo passage to a cargo area through a nominal roof plane or to allow open air space above a third passenger seating row. In at least some operating conditions, front and rear sunroof panels 63 and 71, respectively, are independently operably relative to each other, while central sunroof panel 67 is passively driven by movement of front sunroof panel 63.

Referring to FIGS. 12, 13, 21B, 21C, 21D, 24B, 25, 28B, 29B and 41, a single extruded track 101 is mounted to each side rail of the stationary vehicular roof and elongated in a predominantly fore-and-aft longitudinal direction. Thus, a single common track is used for all of the left-hand movement mechanisms, and another single common track is used for all of the essentially mirror image right-hand movement mechanisms. Each track 101 has a water drain trough 103, a first guide channel 105, a second guide channel 107, a drive cable channel 109 which moves a Bowden-type cable 111, and a third guide channel 113. Sunshades 115 are movable within a sunshade channel 117 below and generally parallel to one or more of three sunroof panels. An electric motor actuator 119 (see FIG. 2) is secured to a front of the tub frame below a wind deflector assembly 121 (see FIG. 13). Cable 111 is automatically pushed and pulled by actuator 119 within a cable sheath 123. A run-out sheath 125 is also attached to a front corner drain trough 127 (see FIG. 13).

A middle track insert 131 is attached to track 101 and has a camming slot 133 with a first longitudinally elongated section 135 and a second generally diagonally angled section 137 blending into second channel 107 of track 101. A front track insert 139 is also attached to track 101 and has a generally diagonal camming slot 141 downwardly and rearwardly declining, and blending into first channel 105 of track 101.

Front movement mechanism 65 can be observed in FIGS. 13-21. A front slide block 151 includes a body 153, roller or rectangular slide feet 155 laterally mounted on each side of the body, a cable retainer 156 projecting from a side of the body, a camming section 157 extending from a leading end of the body, a housing 159 mounted to a top of the body, and a downwardly and rearwardly declining ramp 161 extending from a trailing end of the body. Camming section 157 has a pair of parallel and generally vertically planar walls 163 connected at their bottoms by a plate 165. A diagonally elongated camming slot 167 upwardly and forwardly inclines from body 153. Walls 163 are spaced away from each other with a top-accessible gap therebetween to allow passage of a coupled bracket. A top opening 169 is located in each slot 167 adjacent body 153, with a bridge 171 spanning across the slot in a laterally offset manner, to allow insertion of a laterally projecting cam follower pin 173 which thereafter rides along slots 167. Pin 173 is attached to a primary front bracket 175 which is mounted to a secondary front bracket, that is in turn, attached to a frame 177 adhered to an interior surface of front sunroof panel 63.

Housing 159 has a generally inverted-U shape with a predominantly vertical planar wall 191. A generally vertically elongated and closed slot 193 is disposed in wall 191 of housing 159. A middle of a front panel lock pin 195 selectively rides up and down within slot 193 of housing 159, an inboard end of pin 195 rides fore-and-aft or diagonally within the camming slot of middle track insert 131 and an outboard end of pin 195 is selectively engagable with its central panel locking hook.

Front movement mechanism 65 further employs a lift arm link 201 that is pivotally attached to the body of front slide block 151 and is pivotally attached to front bracket 175, by fixed axis pivots 203 and 205, respectively. A guide pin 207 (see FIG. 19) couples lift arm link 201 to camming slot 141 of front track insert 139. Supplemental panel locks 209 are stationarily attached to track 101 and have a lateral pin which selectively engages a receptacle of secondary bracket 176 when front sunroof panel 63 is in its closed position. The operation of front movement mechanism can be observed in FIGS. 30-35 where FIG. 30 represents the closed position, FIG. 31 represents the venting position, and FIG. 34 represents front and central mechanism engagement.

Central movement mechanism 69 is illustrated in FIGS. 18, 19, 24A, 24B and 26. Central sunroof panel 67 has a peripheral frame 251 adhered to a bottom surface thereof, with a generally L-shaped bracket 253 having a generally vertical and fore-and-aft elongated wall 255 extending down therefrom. Rollers or slide feet 257 laterally project from wall 255 for engagement within third guide channel 113 (see FIG. 12) of track 101. A bifurcated hook 259 forwardly projects from wall 255 and has a diagonally open receptacle 261 selectively aligned with diagonal camming slot section 137 of cam insert 131. When the front sunroof panel and front movement mechanism 65 have been partially rearwardly moved to the position shown in FIG. 34, then pin 195 is downwardly moved within slot 193 by diagonal camming slot 137 in order to engage within receptacle 261 of hook 259. This rearward movement of front movement mechanism 65 further causes ramp 161 to upwardly drive locking pin 281 within a pair of generally vertical slots 283. Slots 283 are located in a generally inverted-U shaped housing 285 affixed to an inside surface of bracket 253. This causes the crosscar elongated locking pin 281 to rise over an abutment surface 287 of a stop 289 which is stationarily attached to track 101. In its closed position, central sunroof 67 is positionally secured by abutment of pin 281 against abutment surface 287. An extension spring downwardly biases pin 281. Furthermore, a slide or roller foot 291 slidably rides within the second guide channel of track 101. Thus, disengagement of locking pin 281 from stop 289 and engagement of pin 195 with hook 259 allows central movement mechanism 69 and central sunroof panel 67 to be passively driven fore-and-aft by front movement mechanism 65 and front sunroof panel 63, for example, from the position shown in FIG. 34 to that shown in FIG. 35. Moreover, a double bulb weatherstrip 293 is mounted in a crosscar extending drain trough 295 in order to seal against the bottom of frame 251 of front sunroof panel 63.

Rear sunroof panel 71 and its associated movement mechanism 73 are independently driven by a rear electric motor actuator 301 (see FIG. 2) via a Bowden-type cable. Rear movement mechanism 73 can best be observed in FIGS. 22, 23 and 25-29B. Rear movement mechanism 73 includes a four-bar linkage assembly 303, a rear slide block 305 and a rear panel carriage 307. These act in concert with a rear panel carriage lock 309 and a rear track insert 311. Four-bar linkage assembly 303 has a generally straight leading link 313 and a generally straight trailing link 315. An upper end of each link 313 and 315 is pivotally attached to a bracket 317, which is attached to an underside of a frame 318 peripherally adhered to rear sunroof panel 71, by fixed axis pivots 319. A lower end of leading link 313 is pivotally connected to rear panel carriage 307, adjacent laterally extending rollers or slide feet 331, about a fixed axis pivot. A lower end of trailing link 315 has a fixed axis pivot 335 connected to a hook 337 rearwardly projecting from rear panel carriage 307. Trailing link 315 further includes a cam follower pin 339 laterally projecting from a middle portion thereof. Cam follower pin 339 rides along an angled camming path 341 in rear slide block 305.

A rear panel locking pin 351 extends in a crosscar direction with a proximal end acting as a cam follower riding in a camming groove 353 in rear track insert 311. Camming groove 353 has a generally fore-and-aft and horizontally elongated rear section and a front diagonal section that is forwardly declining. An opposite distal end of rear panel locking pin 351 rides within a generally vertical slot 355 (see FIG. 36) of rear slide block 305. A rearwardly open receptacle 357 of hook 337 is selectively aligned with the diagonal section of camming groove 353 of rear track insert 311 to receive an intermediate section of rear panel locking pin 351, whereafter the hook and rear panel carriage lock 309 are secured and locked in a closed position.

An extension spring 360 runs from a hole 361 in rear panel carriage lock 309 to a post 363 from rear panel carriage lock 309 in order to bias the carriage lock down into a receiver 365 stationarily secured to track 101. A ramp 371, shown in FIGS. 38 and 39, forwardly projecting from rear slide block 305 operably contacts against and upwardly disengages a trailing end of rear panel carriage lock 309 from stationary lock receiver 365 to allow for continued forward movement of rear sunroof panel 71. The movement of rear sunroof panel 71 and its associated rear movement mechanism 73 can be observed with reference to FIGS. 36-40. In its closed position, the four-bar linkage assembly is upwardly extended and both locking devices are in a locking orientation. However, forward movement of rear slide block 305 causes four-bar linkage assembly 303 to collapse and further forward movement causes unlocking of the locking devices 351 and 309. Thereafter, rear sunroof panel 71 is moved to its open position beneath central sunroof panel 67.

While the multi-panel sunroof has been disclosed, it should be appreciated that other variations fall within the scope of the present invention. For example, two or more central sunroof panels and their associated movement mechanisms may be provided. Furthermore, a central sunroof panel may be actively driven by its own actuator although some of the advantages of the present invention may not be realized. Additionally, it is envisioned that alternate camming, linkages, or track configurations can be employed although various packaging advantages may not be achieved. Alternately, the central sunroof panel can be stationary and immovably affixed to the tracks with brackets, but with the common tracks still being employed. In another alternate embodiment, the rear header panel moves with the rear sunroof panel. It is further envisioned that some of the mechanisms disclosed herein can be used with a single panel sunroof although many of the advantages of the present invention will not be observed. The present invention can also be part of a modularized and preassembled unit including a roof rack, headliner, sun visor assist handles and overhead entertainment console, with a single electrical connection. It is intended by the following claims to cover these and any other departures from the disclosed embodiments which fall within the true spirit of this invention. 

1. A sunroof locking system comprising: a first sunroof panel movable from an open position to a closed position; a first movement mechanism coupled to the first sunroof panel, the first movement mechanism including a cable-driven slide block operably moving the first sunroof panel, the slide block including a camming slot and a ramp, the ramp being located on a different portion of the slide block from the camming slot; a second sunroof panel movable from an open position to a closed position; a bracket coupled to the second panel; and a lock coupled to the bracket, and a portion of the lock being movable in a substantially vertical direction due to selective contact with the ramp of the slide block, the movable portion of the lock being elongated in a substantially crosscar direction.
 2. The sunroof locking system of claim 1, further comprising a stationary structure including a substantially vertical abutment surface, the movable portion of the lock selectively contacting against the abutment surface when the movable portion is in a lowered position, in order to secure the second panel in its closed position.
 3. The sunroof locking system of claim 2, wherein the first movement mechanism slide block slides along a fore-and-aft extending track and the abutment surface is stationarily attached to a portion of the track.
 4. The sunroof locking system of claim 2, wherein movement of the slide block causes the ramp to disengage the moveable portion of the lock from the abutment surface thereby releasing the second panel from its secured closed position and allowing the second panel to move.
 5. The sunroof locking system of claim 1, wherein the lock further comprises a substantially inverted-U shaped housing having a substantially vertically and linearly elongated slot, and the movable portion of the lock is an elongated pin which extends through the slot.
 6. The sunroof locking system of claim 1, further comprising an electromagnetic actuator operably driving a cable connected to the slide block, the bracket including track-engaging guides, the bracket being passively driven by the slide block.
 7. The sunroof locking system of claim 1, further comprising a biasing member biasing the moveable portion of the lock to a lowered position.
 8. The sunroof locking system of claim 1, wherein the first sunroof panel is one of a frontmost or rearmost sunroof panel, the second sunroof panel is an central sunroof panel and further comprising at least a third sunroof panel moveable from an open position to a closed position.
 9. The sunroof locking system of claim 1, wherein the lock when in a first position is operable to lock the second panel in a closed position and when in a second position is operable to allow the second panel to be passively driven by the first movement mechanism.
 10. A sunroof locking system comprising: a first sunroof panel movable from an open position to a closed position; a first movement mechanism coupled to the first sunroof panel; a camming slot having a channel with a first section extending in a substantially horizontal and fore-and-aft direction and a second section extending in a substantially diagonal direction; a bifurcated hook projecting from the first movement mechanism and aligning with the second section of the camming slot when in a selected first sunroof panel position; and a locking pin movable along the camming slot and selectively engagable with the hook thereby securing the locking pin to the hook.
 11. The sunroof locking system of claim 10, wherein the camming slot is part of a fore-and-aft extending track along which the first sunroof panel moves between the open and closed positions.
 12. The sunroof locking system of claim 10, wherein the opening of the hook extends in a substantially forwardly and upwardly angled orientation.
 13. The sunroof locking system of claim 10, wherein the opening of the hook extends in a substantially rearwardly and upwardly angled orientation.
 14. The sunroof locking system of claim 10, further comprising: a second sunroof panel movable from an open position to a closed position; and a second movement mechanism coupled to the second panel; wherein the pin operably moves fore-and-aft with the second movement mechanism and the hook moves fore-and-aft with the first movement mechanism; and wherein engagement of the locking pin and hook serve to lock together the first and second movement mechanisms for at least partially simultaneous opening and closing of the first and second sunroof panels.
 15. The sunroof locking system of claim 10, wherein the camming slot is stationary and the hook is attached to the first movement mechanism, and the first sunroof panel is a rearmost one of multiple sunroof panels.
 16. The sunroof locking system of claim 10, wherein the sunroof mechanism further comprises a four bar linkage assembly, a cable-driven slide block, and a cam follower projecting from the four bar linkage assembly riding along a camming path within the slide block.
 17. The sunroof locking system of claim 10, further comprising: a second sunroof panel movable from an open position to a closed position; a second movement mechanism coupled to the second panel; a third sunroof panel movable between a closed and an open position; and a third movement mechanism coupled to the third sunroof panel; the forwardmost and rearwardmost of the sunroof panels being at least partially movable independently of the other, and the forwardmost and central of the sunroof panels being at least partially movable in unison due to engagement of the locking pin and hook.
 18. The sunroof locking system of claim 10, wherein the selected first sunroof panel position is a closed position.
 19. A sunroof locking system comprising: (a) a movable slide block further comprising: (i) a body elongated in a substantially fore-and-aft direction; (ii) a pair of parallel walls having diagonally elongated camming slots therein projecting from a leading end of the body, an opening located in at least one of the walls between the camming slot and the body; (iii) track-engaging feet transversely extending from the body; (iv) a cable retainer transversely extending from the body; (b) a sunroof panel movable from an open position to a closed position; and (c) a bracket downwardly extending from the sunroof panel and having a transversely extending cam follower; the cam follower being insertable into the opening of the slide block to allow access for the cam follower to thereafter ride within the camming slots.
 20. The sunroof locking system of claim 19, further comprising a link have a first end pivotally attached to the slide block and having an opposite end pivotally attached to the bracket.
 21. The sunroof locking system of claim 19, wherein the slide block further comprises a ramp extending from a trailing end of the body in a downwardly and rearwardly projecting orientation. 